Two-dimensional (2D) materials are gaining global attention for their potential to revolutionize electronics, offering ultrathin, flexible, and highly conductive properties. Among them, graphene stands out as an advanced and versatile material, with applications ranging from high-speed transistors to next-generation supercapacitors.
Black Swan Graphene is focused on moving graphene from research labs to real-world industrial use. The company is advancing scalable and cost-efficient graphene production, paving the way for broader applications of the material in electronics and manufacturing.
The promise of graphene in electronics
Graphene, a two-dimensional material just one atom thick, is emerging as a game-changer in the world of advanced technology. It is capturing the attention of scientists and industry experts for its impressive properties, including excellent electrical and thermal conductivity, flexibility, and strength. Its transparent, ultra-thin structure makes it a promising material for the development of next-generation technologies.
However, despite its potential, graphene has yet to see widespread commercial use. The main obstacle lies in production. Current manufacturing techniques often face high costs, limited output, and inconsistent quality, making it difficult to scale graphene for broader industrial and electronic applications.
Further reading: Find out more about Graphene and 2D Materials in our 2025 Top Technology Trends Report.
From research to scalable production
Black Swan Graphene is moving from laboratory research to industrial-scale production, building on more than a decade of development by UK-based Thomas Swan & Co. Ltd., a recognized leader in advanced materials.
The Canadian company was formed through a joint venture between Thomas Swan and Mason Graphite Inc. As part of the agreement, Black Swan acquired patented graphene production technologies, while Thomas Swan retained a minority stake and licensing rights.
In 2024, Black Swan accelerated its push toward commercialization with the launch of its Graphene Enhanced Masterbatch™ (GEM) product line. These graphene-infused polymer materials are now undergoing industrial trials in markets around the world.
The company is focused on driving large-scale adoption of high-performance, cost-effective graphene across priority sectors such as concrete, polymers, and lithium-ion batteries. It is also building a sustainable supply chain by combining its proprietary technology with access to Quebec’s low-emission hydroelectric power.
Market strategy and global expansion
Black Swan is scaling up production through modular manufacturing systems built for industrial output. A recent expansion at its Consett facility in the United Kingdom is set to triple capacity to 140 tonnes per year. This move is supported by new equipment, infrastructure upgrades, and a growing team in sales and operations to meet commercial demand.
In construction, Black Swan is working with Concretene to develop graphene-enhanced concrete that reduces cement usage and emissions. In polymers, it is partnering with Hubron International to integrate graphene into masterbatch products for plastics. A recent distribution agreement with METCO Resources in India signals the company’s growing global footprint.
As research into neuromorphic computing increasingly turns to 2D materials, Black Swan’s advancements in graphene technology highlight its potential across next-generation applications (see our related blog: Thin, Smart, and Patented: 2D Materials in Neuromorphic Computing).
This article examines the company’s patenting strategy and how it has supported the transition from early-stage R&D to global commercialization, highlighting key IP and legal partnerships along the way.
Black Swan Graphene: Patenting Activity
As of this writing, Black Swan Graphene holds 11 active patents and can be grouped into the following patent families:
| Patent Family | Title | Priority Date | Filing Date |
| US11565269 | Apparatus and method for bulk production of atomically thin 2-dimensional materials including graphene | 2016-10-13 | 2021-03-31 |
| US12318709 | Process for the continuous production of sub-micron two-dimensional materials such as graphene | 2015-11-27 | 2021-08-17 |
Black Swan Graphene holds nine patents under the ‘269 patent family, along with one additional patent under the ‘709 patent family. Developed during Black Swan’s collaboration with Thomas Swan & Co. Ltd., these filings reflect early breakthroughs in scalable graphene manufacturing. Although the company has a growing international footprint, its patent activity over the past decade has been largely concentrated in the United Kingdom, where its foundational technologies were first developed.
After forming in 2021 through a merger with Mason Graphite, Black Swan shifted focus from patent filings to scaling operations. Going public in 2022, the company began leveraging its existing IP to support industrial-scale production. With its foundational technology already protected, Black Swan has since prioritized product rollout, launching its GEM™ polymer line in 2024 and expanding industry testing.
Black Swan Graphene: Top Law Firms
Black Swan Graphene’s global patent filings between 2015 and 2025 were led by a select group of intellectual property law firms, with Canadian-based Robic emerging as the top firm. Other prominent firms include Beijing Hua Law Firm and Fogg & Powers LLC. IP March appears with one filing.
Black Swan Graphene: Top Technology Areas
Black Swan Graphene focused most of its patent filings on materials science and nanotechnology, with the largest portion classified under non-metallic elements and their compounds (C01B). Significant filings also appear in crushing and milling processes (B02C) and metal-containing compounds not classified elsewhere (C01G), pointing to efforts to refine production techniques and develop advanced graphene composites.
A notable portion of patents falls under specific uses and analysis of nanostructures (B82Y), signaling the company’s drive to harness graphene’s nanoscale properties for commercial and industrial applications. Smaller clusters of activity include separation (B01D), chemical and catalytic processes (B01J), centrifuges (B04B), layered products (B32B), and water and wastewater treatment (C02F).
Black Swan’s patented methods for graphene production
The cornerstone innovations in Black Swan Graphene’s intellectual property portfolio, paving the way for efficient, high-quality graphene production, are highlighted in the following section.
A scalable method for continuous graphene production
Scaling up graphene and other two-dimensional (2D) materials requires more than standard separation methods. It calls for systems that can run continuously, avoid clogging, and maintain product quality without damages. Traditional centrifuges often struggle with inconsistent output, turbulence-related particle damage, and frequent maintenance, limiting their effectiveness in industrial settings.
U.S. Patent No. 12,318,709 introduces a solution through a specialized system for the continuous separation of sub-micron 2D materials such as graphene, boron nitride, and molybdenum disulfide. The patent details the use of a disc stack centrifuge, which operates in a continuous mode to separate a solid suspension into fine, sub-micron particles and a residual fraction. Unlike traditional batch centrifuges, this system allows simultaneous input and output, improving throughput and process control.
The system works by carefully controlling factors like the angle of the spinning discs, how fast the liquid flows, and how quickly the centrifuge rotates, up to 12,000 times per minute. This creates very strong spinning forces, allowing tiny, flat particles like graphene to be separated based on their size and thickness without being damaged. The process is designed to run smoothly without causing clogs or turbulence and can handle large volumes of material, from 50 to 4,000 liters per hour. It also works well with a wide range of materials that have been partially broken down in earlier steps.
The patent, titled “Process for the Continuous Production of Sub-Micron Two-Dimensional Materials Such as Graphene,” was filed on August 17, 2021, and granted on June 3, 2025. The inventors are Paul Ladislaus and Lee Glasgow. Legal representation was provided by Robic, with attorneys Louise Bernier, Nathalie Jodoin, Daniele Ethier et al. handling the application.
A durable system for high-quality graphene delamination
Transforming raw graphite into ultra-thin layers such as graphene remains one of the most complex challenges in large-scale materials manufacturing. The process demands precision to ensure high output while preserving the structural integrity of the final product. Traditional exfoliation methods have struggled to meet industrial needs, often hampered by clogging, inconsistent results, and regular maintenance interruptions that disrupt continuous production.
U.S. Patent No. 11,565,269 addresses this challenge through an innovative delamination system designed for large-scale, reliable graphene production. It features a high-pressure pump that drives a suspension of solid particles through a precision-engineered impact head. This head, built with a narrow and adjustable gap, generates intense shear forces that peel bulk materials into atomically thin layers.
What makes the design particularly effective is its durability. The head’s symmetrical shape allows it to rotate, distributing wear evenly and extending its service life. It also includes a self-unblocking mechanism that clears buildup automatically, making it well-suited for continuous, large-scale production with minimal maintenance and downtime.
The patent, titled “Apparatus and Method for Bulk Production of Atomically Thin 2-Dimensional Materials Including Graphene,” was filed on March 31, 2021, and granted on January 31, 2023. The inventors are Paul Ladislaus, Lee Glasgow, and Ronan McHale. Legal representation was provided by Fogg & Powers LLC, with attorneys Gregory Taylor, David Fogg, Paul Bernkopf et al. on the application.
